VIBRATING SCREEN

WITH SERIES V-100

VIBRATORS

TRANSPORTABLE CRUSHING UNITS

MB-231

IMPORTANT
It is obligatory to follow the recommendations
of the safety manual S200.006
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CONTENTS
Page

1. INTRODUCTION ................................................................................................................. 1

2. PREVENTIVE MEASURES FOR LONG STAND-STILLS .................................................. 1

3. INSTALLATION .................................................................................................................. 1

4. WELDING............................................................................................................................ 3

5. CHECKS AND REGULAR MAINTENANCE....................................................................... 3

6. SUPPORT SPRINGS .......................................................................................................... 5

7. CHANGING SPEED AND AMPLITUDE ............................................................................. 6

8. LUBRICATION (GREASE) ................................................................................................. 6

9. DRIVE.................................................................................................................................. 7

10.SCREEN SURFACE ELEMENTS AND RESPECTIVE FIXATIONS.................................. 7

11.DUST ENCAPSULATION .................................................................................................. 8

12.MAINTENANCE ROUTINE ................................................................................................ 9

13.VIBRATING MECHANISM............................................................................................... 10
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MAINTENANCE INSTRUCTIONS

1. INTRODUCTION

The personnel responsible for the operation of the machine must be well informed about its
operation and design and must know when and how to carry out the necessary adjustments.

Thus, they must carefully read this whole manual, and study and understand the illustrating
drawings before installing or operating the equipment. Besides, check that the machine
operator(s) has (have) a copy of this manual readily accessible.
This instruction manual contains the information necessary to monitor and maintain your
equipment in satisfactory conditions of use. If you wish to obtain the maximum availability and
economic life from the machine, our instructions must be followed carefully. Inadequate lubrication
or negligence in repairing apparently insignificant defects may rapidly cause more serious
problems, resulting in burdensome loss of time.
Especially in the case of new or recently installed equipment it is particularly important to follow
carefully the operation and maintenance instructions, both necessary to attend to the terms of the
warranty and to ensure the correct operation of the machine.
In all contacts and correspondence exchanged with the manufacturer, the type, model and series
number of the equipment must be mentioned. These data can be found on the machine
identification plate.
If you run into a problem not mentioned in this manual, or miss some information that you consider
relevant, please enter in contact with the nearest SANDVIK distributor or directly with SANDVIK.
We recommend to read the manual MB–115, which contains additional information about vibrating
equipment in general.

2. PREVENTIVE MEASURES FOR LONG STAND-STILLS

If the equipment is not put into operation immediately after the delivery, or if it is standing still for
more than one month, lubricate the roller bearings with grease at least once every month to avoid
corrosion. Rotate the shaft(s) a few turns manually or use the motor, if this is available, so that the
grease would be distributed evenly in the bearings. If the equipment is to be stored outdoors,
cover the bearing houses in order to avoid condensation in the roller bearings.

3. INSTALLATION

In addition to the instructions presented here, please also look up the Section 4 – Welding.

3.1 Make sure that the supporting structure is sufficiently stiff. This guarantees the correct inclination
of the equipment and the levelness of the corresponding points on both sides. Use a plastic hose
with water for leveling and check at the extreme ends of machine and support structure.

3.2 Remove the lifting crossbars and the transport locking devices (if your model have those) and put
them away for future transports.

3.3 Do not add spouts, chutes, feed boxes, deflectors or any other items to the vibrating body.
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3.4 Direction of shaft rotation: Normally the flow is in the material flow direction, as the figure shows.
Only in very special cases the counter–flow direction is recommended and may present some
advantage.
Horizontal screens and vibrating feeders require that the shafts rotate in opposite directions. The
horizontal screens may show different behaviors for each of the chosen directions (see figure at
right below). The one that brings out the best results shall be adopted.

3.5 Drive
Make sure that the structure is sufficiently stiff for not vibrating during work. Always check the
tension of the V–belts and check that all bolts are tight.

3.6 Make sure that the respective guards and protections are installed over the rotating parts.

3.7 Install the screen components if they were not delivered as already installed.

3.8 Make sure that all nuts and bolts are tight.

3.9 Make sure that all roller bearings have been lubricated.

3.10 Start the equipment. Check that there is no strange noise and that the roller bearings are not
showing any abnormal heating.
During the first 100 hours of operation, the re–lubrification intervals must be cut in half. Check,
during the initial operation period, the tightness of all bolts and the tension of the V–belts more
often than you would normally do.

3.11 Maintain a minimum distance of 80 mm (≈ 3 in.) between any stationary element and the
vibrating body of the equipment.

3.12 The discharge spouts or chutes must be planned considering the necessity of access for
changing any part that is a reposition item.
3.13 Do not add any higher lateral sides at the extreme end of the feeder. If they are required, make
them stationary.
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4. WELDING

If possible, avoid to carry out welding on the vibrating body. Welds may cause dangerous stress
concentrations and cracks. If welding is inevitable, it is important that it shall be carried out in a
correct manner. The safest way is to consult us, and for that we are always available for you.
It is extremely important to fix the negative pole adequately to the part to be welded. The electric
current must not pass through a roller bearing.
If the current passes through the roller bearing, the damage may so serious that it would have to
be replaced.

NOTE: Never open holes in the vibrating body because these may initialize the forming of cracks.

WELDING ON THE MACHINE FRAME

If a crack appears on the machine body because of wear of fatigue, the following procedure shall
be followed:

1. Localize the extreme ends of the crack and drill

a 6,5 mm (1/4 inch) hole at each end to avoid
the propagation of the crack.

2. Open up the crack with an adequate round end

rotating file or mounted grinding point or with a (1)
carbon electrode.

3. Pre–heat to around 800 C (1720 F), especially in

the crack region.

4. Weld with dia. 3,o mm (~1/8 inch) AWSE 7018

electrode to avoid cracks and gas craters.
Debar the other side of the crack and weld it,
obtaining, if possible, full penetration. (Use the
electrode AWSE 6010 para vertical and
overhead welds).

5. Debar the welding slag.

5. CHECKS AND REGULAR MAINTENANCE

Check the following points when the equipment is working:

5.1 Make sure that the material is being fed uniformly, and if possible, over the whole width. The
material must fall on the part of the surface provided with a wear liner, and not straight on the
screening medium, to avoid unnecessary wear. This is especially important when using screening
media with very small aperture sizes.
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5.2 Check the movement of the screen using amplitude registration cards and check for a possible
occurrence of critical frequency.

Because of possible damage occurred during transport, during mounting, or because of natural
wear, the screen must be inspected to make sure that it is not operating at the critical speed.
Check this as follows:

5.2.1 Attach firmly four cards about 80 mm x 140 mm (≈ 3 in x 5 in) at the four extreme corners of the
equipment, using an adhesive tape. Place the cards exactly in the same positions, at the feed
and discharge ends, and on both sides. After fixing the cards, trace a horizontal line on the
uppermost part of each in order to be able to determine the exact angle of the movement.

5.2.2 Use some support that lets you secure firmly a pencil or ballpoint pen, at the same height in
relation to every card, and very close to the cards. Rest the support on the ground and
vertically in relation to the card so that the pencil or similar, rigidly fixed to this support, touches
the card only lightly. This procedure is impossible to carry out correctly with a free hand,
without the help of a firm support.

5.2.3 With the screen operating at full speed, and with the pencil square to the card, touch
momentarily the card in a series of points. Make sure that the pencil is secured firmly, in order
to avoid secondary movements in the register tracing.

5.2.4 Fill out all the four cards, and write down on each one its localization. Make a note, too, about
the serial number of the equipment, the work site, and the name of the person that performed
the tracing job.

5.2.5 If the profiles or forms of the movements, registered on each side at the feed end, are not
practically identical, and if the same thing occurs at the discharge end, it is an indication that a
critical speed condition has occurred. The reason may be damage during transport, during
installation or because of screen wear. Usually a condition of critical speed has occurred if the
screen amplitude at two diagonally oppose corners is appreciably smaller than that of the other
diagonal.
When a condition like this takes place, the screen in general also presents a small lateral
movement. Because of this, it becomes difficult to register the complete movement of the
amplitude with the pencil or ballpoint square to the cards. The alternative in these cases is to
secure the writing instrument in an inclined position in relation to the paper and thus
accompany the lateral movement.
If a critical speed condition occurs, check the following points:
a. The compression of the support springs. The springs at the feed end must be equally
compressed. The same must be the case at the discharge end.
b. The screening media and their respective fixation elements must be well installed and
tightened.
c. If the screen surface shows clogging and aggregation of material, clean and remove.
d. Check that the suspension cables do not move excessively. Adjust the stabilizers, if
necessary.
e. Check that all bolts and nuts are adequately tightened.
After checking all these points, make a second test registering the amplitudes on the same
cards. Send all four cards to the manufacturer, together with all pertinent data. It is
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important that this is made as fast as possible, because the continuous operation of the
screen in the critical speed condition may cause sizeable damage.
If the two amplitude graphs registered at the feed end are practically identical, and the
same occurs at the discharge end, the screen is behaving correctly and as expected.
Make this inspection regularly and save the cards for comparison. This procedure is easy,
cheap and the best way to check the health of the screen.

6. SUPPORT PRINGS

The set of support springs is designed in such a way that it is easy to substitute springs without
lifting the equipment very much. When replacing springs, proceed as follows.

6.1 Remove the bolts that secure the upper and lower spring disks.

6.2 Lift the part in question, with the help of a hydraulic jack or other lifting device, until the springs
become unloaded (40 mm, ≈ 1- 5/8 in). In this instant the springs and their respective guide
disks may be moved laterally and removed.

6.3 Make sure the new spring(s) has (have) correct dimension and that they are identical to the
replaced one (ones). Check the diameter of the spring wire.

6.4 Install the new spring set in the reverse order. We recommended that you always change springs
in pairs, that is, replace the spring that presents the problem and its twin on the opposite side of
the equipment.

6.5 When the equipment is again supported by the springs, check the spring height on both sides. In
order to have the equipment work in the correct way, the spring heights must be equal. The
heights at the feed end may be different from the ones at the discharge end.

6.6 Friction brakes are supplied as standard components on almost all vibrating machines, but may
be optional in some cases. These elements reduce the amplified spring movement that takes
places at starting and stopping.
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7. CHANGING SPEED AND AMPLITUDE

The equipment is delivered with rotation and amplitude adjusted to the adequate values. If
necessary to change these values, we recommend that you first contact the manufacturer. Even
small alterations of rotation or amplitude may bring about great changes of the roller bearing life
and of the equipment performance.
In principle, in order not to modify the calculated roller bearing life, the rotational speed of the
machine must be reduced when the amplitude is increased. The contrary is also valid, that is, the
rotation may be increased when one reduces the amplitude.
Amplitude changes are made in the following way: Remove the drive connections and the external
guards; comply exactly with the schemes that orient the desired configuration of the
counterweights; never use speeds exceeding those indicated as limits; make sure that the same
configuration is applied to all vibrators installed on the same machine, see also the section 13.
Vibrating Mechanism.
After making any adjustment, check that the movement is equal at both sides of each end.
8. LUBRICATION

A correct lubrication using an adequate lubricant is essential for attaining the calculated useful life
of the roller bearings.
Use always grease in accordance with the requirement contained in 12. Maintenance Routine.
Utilizing a lubricant of inadequate type or quality, you run the risk that hard spots are being
formed. These may cause damage to the roller bearings and clogging of the grease lubrication
channels. Never mix greases of different types or brands.
Before carrying out the lubrication, clean carefully the lubrication point and the grease nipple, to
avoid the transport of contaminants to the roller bearings when injecting grease.
The storage that houses lubricants and lubrication equipment must be protected against dust,
water and other matters that is harmful to grease. Never use contaminated lubricants.
Besides its lubricating function, grease acts as a sealing agent, thus avoiding that dust and other
harmful substances enter the roller bearings. If the equipment is being used in extremely dusty
environments, the lubrication intervals given in 12. Maintenance Routine must be diminished, and
the quantity injected every time, reduced.
To avoid start–up difficulties, especially under low–temperature conditions, operate the equipment
until it reaches working temperature, and first then lubricate. Operate a little, once again, after
lubrication, to distribute the grease to labyrinths in an adequate way before they cool off.
The vibrating mechanism lubrication is by means of oil bath, and there is a transparent oil-level
indicator located as function of the equipment slope.

There is one individual point of injecting provided for every vibrator. Look up the characteristics of
the recommended oil in the Section 13. Vibrating Mechanism.
The shaft that connects opposed vibrators shall be lubricated only when the vibrators are
dismounted. This is partly because difficult access, and partly because of lack of relative
movement (that would cause wear) between its components during normal operation.
The universal joint shaft that connects the vibrator to the motor drive shall be lubricated at the
same intervals as the vibrators. The roller bearings of the driven pulley have permanent
lubrication.
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Just after the newly lubricated equipment has been started, the bearing temperature usually
exceeds somewhat the normal one. If the increase is moderate and the temperature returns to
normal after a short time, no damage will be caused to the bearings.
The lubrication intervals, quantities and recommendations may be found in the Sections
12. Maintenance Routine and 13. Vibrating Mechanism.

9. DRIVE

The majority of the machines are driven by electric motors through a transmission that consists of
a driving pulley, V–belts, a driven pulley with roller bearing mounted on a fixed shaft, and a
universal joint shaft. Some machines are driven directly by a motor and a universal joint shaft and
others utilize a motor with pulleys and V–belts.
When you replace V–belts, we recommend that you always use complete sets of new belts, and
preferably of the Power–Band type. This is because the individual belt lengths, even of new belts,
vary considerably. If one belt is damaged, you must replace the whole set, to avoid that some belts
would carry greater loads than the rest. The pulleys that come with deep grooves do not permit the
use Power–Band type belts.
Before installing a new set of V–belts, make sure that the pulleys are free from defects, and that
the belts do not touch the bottom of the grooves.
When you tension the belts, make sure that the motor shaft and the intermediate shaft are parallel
and that the pulleys are correctly aligned.
New belts will get slack more rapidly during the initial operation period. Thus they must be adjusted
more frequently.
Check also that the universal joint drive shaft is correctly aligned, and check that its screws are
tight and properly locked.
The double drives, which operate by self–synchronism, require that pulleys and belts shall be
perfectly equal. In case of wear, we recommend that you acquire new pulleys directly from
Sandvik. This will assure that they are all identical.

10. SCREEN SURFACE ELEMENTS AND RESPECTIVE FIXATIONS

The screens may be equipped with steel wire–cloth, perforated plates, with rubber or
polyurethane screening media. For special applications still other types may be used.
For screening of very fine and difficult materials, we recommend the use of wire–cloth, made of
wire with the smallest possible diameter.
For screening course material, we recommend screening surfaces of rubber, or steel plate for the
upper deck. These elements are available with square or round holes.
There are available several different elements and ways of fixing the screening surfaces. The
choice depends one the adopted surface, every one with its specific features.
Check at regular intervals that the screen elements are adequately tensioned/fixed, especially
when these are new. If this is not the case, the surfaces may be hammering, and that would
reduce their useful life, as well as the proper screening performance.
When you tension screening elements, do it in phases, alternating between both sides.
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11. DUST ENCAPSULATION

Some screens are prepared for an easy installation of encapsulation components. When this is
the case, a series of components must be added to the screen body, besides the supports for the
upper frame of the cover.
The screen body may be supplied complete with the drilled holes needed for the fixation of the
encapsulation components.

In order to obtain the best possible results, we recommend that you use an air exhaustion
system.

When the screen is encapsulated, it is important not to forget to inspect and check regularly the
screen elements, in order to avoid that they work in a loose or damaged condition.
It is also important to hinder that fine material fractions accumulate between the vibrating screen
and the stationary parts of the machine. Otherwise there is a risk that the screen hammers
against the accumulated material, certainly resulting in damage. The probability of this happening
is, of course, greater when an air exhaust system has not been installed.
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12. MAINTENANCE ROUTINE

We are presenting below some guidelines that must followed as a maintenance routine.
Regarding more detailed information or about adjustments or repairs not making part of this
routine, please check the instructions given in the manual. Read carefully the instructions.

INTERVA PROCEDURE REMARKS SECTIONS

L (x)
(hours)
Check for strange noises when If the movement is abnormal, check feed and 5
equipment is operating. amplitude.
0
Check bearing temperatures The bearing temperature must not exceed 60 C
Daily 0
(140 F) over ambient temperature. 8

Check that the screen medium After screen media replacements, re–tighten all
components are fixed correctly. components more frequently.
50
Check that the screen can move Remove all material that has accumulated near to
freely. and on the screen. 10

Lubricate the vibrator roller bearings Keep the machine warm when standing still to
and the universal joint shaft. avoid start–up difficulties (in a very cold climate).
50 Operate machine for a few minutes so that the
During the first 100 hours, lubricate grease gets distributed in roller bearings and
vibrators every 50 hours. 8
labyrinths.
100 Normal operation In very dusty conditions, reduce the lubricating
intervals, and reduce also the grease quantity
added.
Lubricate the vibrator roller bearings – Clean carefully the grease nipples
and the universal joint shaft.
– Follow the grease recommendations
– Do not mix different types of grease
– Do not use contaminated lubricants

Do not fill the roller bearings entirely with grease

200 Check the tightness of vibrator bolts, Re–tighten after every adjustment or maintenance
of guards and other parts. procedure.

Inspect the V–belts (and Check belts for wear, and check tensioning and 9
synchronizer, if one present). alignment.
Always re–install protection guards.

Important
Do not add spouts, chutes, sides, or Enter into contact with the manufacturer about any
any extra parts to the vibrating additional information regarding installation of extra
screen body. components.

x) The section numbers refer to the Maintenance Instructions.

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13.VIBRATING MECHANISM

13.1 Description

The vibrating mechanism type V100 is of the long shaft type with adjustable counterweights at
the extreme points. The mechanism is fixed to the sides of the vibrating equipment by two
flanges, which comprise the bearing houses.

The lubrication is by means of oil bath, and there is a transparent oil-level indicator located as
function of the equipment slope.

In case of slope change on field, the oil-level must be corrected immediately.

The oil-level is obtained tracing the true horizontal line “X” mm apart from the center of the
bearing, according to the table below.

VIBRATOR V-075 V-100 V-120 V-140 V-160

DISTANCE. 55 72 85 102 116
“X” (mm)
APPROX.OIL 4 to 6 5 to 8 6 to 9
VOLUME (l)

The table also shows the average oil volume (liters) for
each vibrator size. The real volume depends on the
length of the shaft and must be found according to the
right oil level.

The vibrator assembly is symmetric and all parts are interchangeable from one end to the other.
Only the main counterweights are identified as left or right construction to make adjustment
errors more difficult.

The drive may be installed freely on one side or the other.

The roller bearings have a sliding fit on the shaft and an interference fit in the housings.
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13.2 Shaft 3705–0

The regions of the shaft which support the roller bearings are precision machined and specially
finished, and shall be checked every time the bearing housings are removed.
The following values apply, as determined by the roller bearings:

Roller Shaft Dia/Tol. Deviations Finish (Ra) Clindricity IT5/2

Bearing mm µm µm µm µm
22320 ∅100/f6 -36 -58 1.6 7.5
22324 ∅120/f6 -36 -58 1.6 7.5
22328 ∅140/f6 -43 -68 1.6 9

The shaft key–ways of the two extreme ends must be perfectly aligned.

13.3 Counterweights (CW)

The CWs are extremely important components, as they determine the amplitude of the vibrating
movement of the equipment. They are carefully fabricated and balanced.
The centrifugal force produced by the rotation of the CWs causes the vibratory motion of the
equipment and depends exclusively on the CWs.
The product of the weight of the CW and the distance between its center of gravity and its
center of gyration is called the eccentric mass, and is represented by “mr”. The latter defines the
performance characteristics of the vibrator.
Changing the relative position between the main CW (thicker) and the movable one, by turning
one in relation the other modifies the value of the mr of the assembly.
The centrifugal force Fc produced by the CWs is proportional to the value of mr and to the
square of the rotational speed rpm: FC = mr x rpm2/91 N [Newton].
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IMPORTANT
Never modify in any way whatsoever the original CWs of your equipment.
Never operate the equipment with CW adjustments or quantities different
from
Those recommended by the manufacturer.

At each end of shaft there are two parts: the main CW 3875–0, locked to the shaft with the key
and the movable CW 3885–0, which turns on the shaft cap and locks to the main CW through a
bolt.

The movable CW has 5 distinct positions, which allow adjustment to approximately 60; 70; 80;
90 and 100% of the maximum value. The possible adjustments are shown on the next page.

To change the adjustment, just remove lock screw 3890–0 and turn the movable CW to the
desired position, and then re–install the lock screw. Repeat procedure for the other shaft end.

IMPORTANT:
The adjustment of the CWs at each end of shaft must be identical. Any difference is likely to
cause torsions in the equipment structure. These may produce cracks and ruptures of
structural elements.
The two opposed main CWs are of differing designs, left and right, to avoid incorrect
adjustments. This will guarantee that the needed rotational direction of the movable CWs is
the same at both ends.
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13.4 Bearing housings

The housings 3605–0 accommodate the roller bearings 3725–0, mounted with an interference
fit. In the same way as the shaft, the areas of the housings that come into contact with the shaft
are precision machined and specially finished. Allowed tolerances, see table below:

Roller Housing Dia/Tol. Deviations Finish (Ra) Clindricity IT4/2

Bearing µm µm µm µm µm
22320 ∅215/P6 -70 -41 1.6 7
22324 ∅260/P6 -79 -47 1.6 8
22328 ∅300/P6 -79 -47 1.6 8

When replacing roller bearings, the dimensions of the housing shall be checked. Substitute it if
necessary.

The correct mounting position is when, with the equipment in the correct operation inclination,
the drain connection is under the center and perfectly vertical.

It is through the housings that one adds and drains lubricating oil, and checks its level.
Each top of housing lodges an air vent.

IMPORTANT
The bearing housing 3605-0 has an external groove for the installation of a rubber O-
ring, to avoid oil leakage.

13.5 Internal flange (3805-0)

Its main function is that of a bearing housing, besides it is the stationary part of the labyrinth.
The mounting position is very important. The indication “UP” must always be up and aligned to
an assumed vertical line passing through the center of the shaft. It is always possible to see the
mark “UP”, even if the movable counterweight would be in front of it.

Between the housing and the internal flange there is a gasket, with a special cut–out that shall
be placed in the lowermost down–position, that is, opposite the “UP” position. This is to make
possible the draining of the oil.

The internal flange lodges a retaining ring 3815–0. Its correct mounting position shall be
observed in order to avoid oil leakage.

13.6 Deflector bushing (3840–0)

This bushing is cylindrical on the inside and conical on the outside. It serves as a spacer, and
together with the internal flange 3805–0 it forms a labyrinth, besides it centrifuges the oil to the
bearing rollers. An internal O–ring completes its fixation to the shaft.
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13.7 External flange (3850–0)

Its function is, being in contact with the retaining ring, to seal against outflow of oil, and to form
the outer part of the labyrinth seal. It is mounted as a sliding fit on the shaft and provided with
an internal O–ring for sealing purposes.

13.8 Spacer tube (3505–0)

The main function of the spacer tube is to protect the shaft.

It also contributes as a structural element, giving stiffness to the assembly by connecting both
side plates. Because of this, the bolts that connect the tube to the housing/side–plate
assemblies must be correctly tightened.
It also forms a communicating vessel and an oil reservoir between the two bearing housings.
The big tube area helps to refrigerate the oil.

If the spacer is equipped with a connection in the lower part, this may also be used for draining
the oil when carrying out oil change.

13.9 Adjustments of the eccentric mass

The eccentric mass of the vibrator, also known as the product “mr”, may be adjusted to five
different values, as already mentioned.

To calculate the vibration amplitude (amplitude = half the throw), multiply the pertinent “mr”
value of each vibrator (see table) by the number (Z) of vibrators installed on the equipment, and
divide the result by the vibrating mass M [kg] of the machine.

amp = amplitude [mm]

amp = mr x Z x 1000 [mm] mr = eccentric mass [kg.m]
M Z = number o vibrators
M = vibrating mass [kg]

13.10 Useful roller bearing life

The useful life of a roller bearing is the period that it works correctly. It is finished when the
components of the bearing have been damaged by fatigue or wear.

IMPORTANT
The useful bearing life depends directly on the quality of maintenance and the attention given
to it by the user.

Generally, the roller bearings that are applied to vibrating equipment are of a special
construction. Always consult with the supplier when buying these.

When vibrating equipment is supplied the machines come with selected roller bearings that
ensure that the bearings, when installed, present the correct clearances for the application.

Thus, when replacing roller bearings it is of extreme importance that they shall be acquired with
the correct radial clearance.
An inadequate clearance may cause overheating and damage the roller bearing.
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You are strongly recommended to order the replacement roller bearings from the original
equipment manufacturer.

The basic condition for a successful replacement of roller bearings is that utmost cleanliness
and extreme care shall be observed when carrying out this task.

13.11 Vibrator maintenance

Definition

By maintenance of vibrators is understood any inspection that implies, or not, in dismounting,

substituting parts, cleaning, lubrication, reconditioning, adjusting, measuring etc., all aiming at
correcting and preventing, or simply checking the state of the components.

Maintenance is necessary in order to:

1. Check the state of all the components.

2. Prevent unexpected stops (preventive maintenance).
3. Correct problems (corrective maintenance).

MOUNTING AND DISMOUNTING

For installing or removing vibrators, at least a manual 500 kg lifting hoist is recommended.
The shaft is the heaviest component. However, it generally remains in the spacer tube, and it is
only rarely replaced.

The bearing housing, because of roller bearing replacements, is the most frequently handled
part.
It is recommended to pull out the housing from the vibrator and to continue the dismounting of it
in an appropriate (clean) place.

DISMOUNTING

To facilitate maintenance we will give some guidelines:

All vibrator components are mounted with clearance fits, except the roller bearings (3725–0) in
the bearing housings (3605–0).

Start the dismounting by removing the counterweights. If the machine has two shafts, first of all,
identify the counterweights and their relative positions in order to ensure their correct re–
installation. Remove the screw M20 from the center of the shaft cap, and the entire
flange/counterweight assembly will come off.

Remove the key to get access to the external (3850–0) and internal (3805–0) flanges.

The internal flange (3805–0) is provided with two threaded holes for extraction.
Remove the flange bolts, and put two of them in the extraction holes and tighten them. Now the
internal flange will come off, bringing the external flange with it.
In the same way as the flanges, the bearing housings (3605–0) also have extraction holes.
Remove the housing bolts, and fit two of them in the extraction holes and tighten them. Now the
housing will come off.
 VIBRATING SCREEN MB-231
WITH SERIES V-100
VIBRATORS May/03 16(21)

Keep the shaft suspended with the help of a steel cable and an M20 eyebolt fitted to the thread
at the shaft end.

After this operation, continue removing the housing gradually until it becomes free from the side
plate.

Install a second shaft lifting means, between the housing and the side plate. Keeping the shaft
suspended, free the first lifting cable to release the housing.

ATTENTION
Never support the shaft on the spacer tube if the housing of the opposite side is mounted. You
may seriously damage labyrinths and seals.

Use a hydraulic press or jack to extract the roller bearings. If not available, use the set–up
shown on the figure below.

To install new roller bearings, heat the housing (3605–0) in an oil–bath or in an oven to 1200 C
(2500 F). Never use a torch or any other method that would direct an open flame towards the
housing, as this would cause distortions.

Let the assembly cool slowly to ambient temperature.

 VIBRATING SCREEN MB-231
WITH SERIES V-100
VIBRATORS May/03 17(21)

MOUNTING

To mount, proceed in the reverse order of that described in the Item Dismounting.

Do not forget, before mounting the internal flange (3805–0), to put the bushing (3840–0) on the
shaft. Observe also the condition of the O–ring.
Recall, when installing the retention ring, that its lip must point inward in order seal–off the oil.

Make sure that the counterweights are correctly installed.

Avoid inverting the sides of the counterweights, as they are differentiated as left and right.

Install the vibrator on the equipment and apply the correct torque to the housing bolts.

Always use only high resistance bolts, nuts and washers as described in next paragraph.

IMPORTANT
In the case of inclined screens, with vibrators between the decks, check the wear of the rubber
blanket that lines the spacer tube. Replace if needed.

13.12 Vibrator mounting Bolts

It is recommended to use only ISO (DIN) 10.9 bolts, or their equivalents SAE GR 8 and ASTM–
A–490. For every bolt there must be two hardened flat washers of equal material class.

Diameter (mm) 12 14 16 18 20 22 24 30 36
Torque (N.m) 8.8 75 128 193 280 385 520 650 1300 2290
Torque (N.m) 10,9 114 181 277 386 541 728 935 1840 3210
Torque (N.m) 12.9 136 217 333 463 649 874 1120 2210 3850

13.13 Lubrication – Vibrators type “V–100”

The lubrication point is the threaded stopper on the upper part of the bearing housing.

The added oil passes through the roller bearing, enters the spacer tube, reaches the bearing
at the opposite side, and arrives finally though an orifice to the level indicator.

The equipment leaves the factory with adequate oil for the first 40 hours of operation. After
this period the first oil change shall be made. The next oil changes shall be carried out after
every 1000 hours of operation, with an analyses each 500 hours. Change the oil anytime, if
the contamination is detected.
 VIBRATING SCREEN MB-231
WITH SERIES V-100
VIBRATORS May/03 18(21)

In case the equipment is to be stored, see the section “Preventive Measures for Long Stand
stills”.

The aim of the labyrinths is to prevent dust from penetrating and damaging the retaining rings.
Grease shall be injected every 100 hours until one can see new grease come out from
labyrinth.

13.14 Recommendations regarding the lubricating oil

When the equipment works in a locale with ambient temperature of 20 C to 400 C (36–1040 F),
the lubricating oil shall obey the following specifications for extreme pressure and high quality.

– High stability against oxidation, with moderate extreme pressure characteristics.

– Minimum tendency to foaming.
– The neutralization number shall be such that the oil does not attack the highly polished
surfaces of the roller bearings even under prolonged periods of operation.
– Oil film resistance at least TIMKEN 40.

– The viscosity shall be:

AGMA MILD Fluid Point Viscosity Seconds Saybolt

Universal (SSU)
EP Number ºC (ºF) 100ºF 100ºC
3 -23 (-9.5) 750 70

The following lubricating oils are recommended:

TEXACO – Meropa 150

GULF – EP Lub HD150
PETROBRÁS – EGF 150 PS
MOBIL – Mobilgear 629
EXXON (ESSO) – Spartan EP 150
IPIRANGA – SP – 150

Recommendations

Never exceed the oil levels that have been defined by the design of the equipment.

The temperature of the lubricating oil must never surpass the ambient temperature by more
than 500 C (1220 F) after 100 hours of operation.

During the first 100 hours of operation the temperature of the lubricating oil must not exceed the
ambient temperature by more than 600 C (1400 F).
 VIBRATING SCREEN MB-231
WITH SERIES V-100
VIBRATORS May/03 19(21)

14. V-BELT DRIVE

Most machines are driven by an electric motor via a V-belt transmission, a stationary
intermediate shaft (with the driven pulley) and a universally (cardan) jointed shaft. Some
machines are driven directly by the motor and cardan shaft and others use motor, pulleys and
belts.

When changing V-belts, it is recommended to always use complete sets of matched belts, as
the lengths of new, unmatched belts may vary considerably. For the same reason, do not
install used belts together with new ones. In the case of damage to individual belts, the whole
set must therefore be changed to avoid subjecting some belts to higher loads than the others.

Before fitting the new set of belts, check that the pulleys are free from defects and that the V-
belts do not touch the bottom of the grooves.
When adjusting the belt tension, make sure that the motor shaft and the intermediate drive
shaft are parallel and that the pulleys are correctly aligned.

New V-belts will stretch quite rapidly during their running-in period. The belt tension must
therefore be adjusted more often when the belts are new.

Check also that the universally jointed shaft between the screen's vibrator mechanism and the
drive assembly is correctly aligned, and that the bolts are tight and locked.

15. CARDON SHAFT DRIVE

The symmetric vibrators V-100 are generally used in pairs and driven independently. This will
cause self-synchronism, as is the case in the majority of the vibratory feeder applications. In
these cases the two vibrators must rotate in opposite directions, and all the elements of the
two drives, including the motors, must be absolutely equal in order to guarantee that both
pairs rotate at exactly the same speed. In case a frequency converter is being used, it must be
one only that feeds both motors simultaneously.

In some cases, as for example vibrating troughs, the vibrators are installed and driven on an
individual basis. The most common rotational direction is the one that is equal to the material
flow direction.

There are also the cases in which these vibrators are installed coaxially and joined by an inter-
connecting shaft, as it generally occurs with the majority of larger equipment. This construction
is used for small screens with linear motion. In this case the vibrators must stay perfectly
aligned, that is, the counterweights of one vibrator must point exactly to the same direction as
the counterweights of the other vibrator, which means that there must be perfect parallelism
between the two.
 VIBRATING SCREEN MB-231
WITH SERIES V-100
VIBRATORS May/03 20(21)

IMPORTANT
Inter-connecting shaft

1. When installing the vibrators, use the opportunity for lubricating manually the splined part
of the shaft.

2. The connecting flanges at the ends are specially machined and assembled in order to
ensure the alignment between opposite vibrators.

3. If a perfect alignment is not obtained when connecting the vibrators, interrupt the
assembly and start the process again.

4. If once again a perfect alignment is not obtained, replace the inter-connection shaft by a
new one. If the misalignment persists, call the SVEDALA Technical Service.

5. If an accident has occurred with shaft components, do not reuse parts, replace the entire
shaft.

IMPORTANT
Bolts

The bolts 3860-8 that fix the vibrator drive (pulley bolts, or universal joint equipped shaft, or
inter-connecting shaft) must always be locked, after the torque has been applied, by means
of a steel wire that passes through holes in the bolt heads. This ensures that they are never
becoming loose by themselves.

The installation of these vibrators on the equipment is always done with flanges and bolts. Only
high-resistance bolts must be used, together with nuts and flat washers of corresponding
quality.

For the dismounting of the vibrators from the equipment, it will be necessary to remove the
counterweights on one side in order to have free passage through the hole. Be careful when
carrying out this operation, because the shaft is a sliding fit in the roller bearings and could
easily fall off.
 VIBRATING SCREEN MB-231
WITH SERIES V-100
VIBRATORS May/03 21(21)

IMPORTANT
Dismounting

When removing the counterweights in order to mount or dismount the vibrator, one must
keep the key fixed to the shaft to hinder the shaft from falling out.

16. SCREENING ELEMENTS AND CLAMPING ARRANGEMENTS

The screen can be fitted with wire cloth, perforated plate, or with rubber or plastic screening
elements. For special applications, other types of screening elements can be used.

When damp, fine material is to be screened, use wire cloth elements with the smallest
possible wire diameter.

If coarse material is to be screened, rubber or plate elements are usually fitted on the top
deck. These elements are available with square or round openings.

There are many clamping arrangements available depending on the kind of screen cloth
adopted, each one with its specific characteristics.

Check at regular intervals that the screening elements are properly tensioned, particularly
when they are new. If they are not properly tensioned they will flap, which shortens their life
and reduces their screening performance.

When tensioning the screening elements, tension in stages, working alternately on both sides.

17. DUST ENCAPSULATION

Some screens are prepared for easy installation of dust encapsulation components. When the
screen is to be encapsulated, a number of attachment strips must be fitted to the screen body
and a supporting frame must be placed on the mounting frame. The screen body is delivered
with holes already drilled for the attachment strip screws.

If the encapsulation is to give best results, an air extraction system should be used.

When a screen is dust encapsulated, it is important that the screening elements are regularly
inspected, to prevent operation with damaged or untensioned elements.

It is vital that fine material is not allowed to build up beneath the screen on structures and
chutes, etc. There is otherwise a risk that the screen body hammers against the accumulated
material with damage as a result. This is especially important if no air extraction system is
used.